Defining Geometry and Process Parameters

Within 3D-CAD, you create the geometry of the film in its undeformed state and then apply design parameters to its length and width. Thereafter, in the simulation setup, you create global parameters for use when defining process conditions at boundaries.

The geometry you create is a rectangle whose width corresponds to half the initial width of the film, (hence 0.1 m), and whose length is that of the film length, 0.23 m. You specifically create the rectangular sketch on the X-Y plane and extrude it in the Z direction so that later you can create a 2D mesh on the X-Y plane at Z = 0.

You define global parameters for the velocity and thickness of the film as it enters the simulation—the die exit velocity and die film thickness respectively. You also define a parameter for the film draw ratio.

To define and parametrize the geometry:

  1. Launch a double precision version of Simcenter STAR-CCM+ and start a new simulation.
  2. Create the geometry that defines the undeformed film:
    1. Right-click the Geometry > 3D-CAD Models node and select New.
    2. In the 3D-CAD panel, right-click 3D-CAD Model 1 > Features > XY and select Create Sketch.
    3. In the Create Sketch Entities group box, click (Create Rectangle).
    4. In the Graphics window, create a rectangle on the sketch plane with the first corner on the origin, position [0 m, 0 m] and the second corner at position [0.23 m, 0.1 m] ending up with a Width of 0.1 m and a Length of 0.23 m.


  3. Define the initial film width and the film length as design parameters:
    1. Right-click one of the vertical lines and select Apply Length Dimension.
    2. In the Dimension dialog, activate Expose Parameter, enter Name as Initial Film Width, then click OK.
    3. Right-click one of the horizontal lines and select Apply Length Dimension.
    4. In the Dimension dialog, activate Expose Parameter and enter Name as Film Length, then click OK.


    5. Click OK to close the Sketch panel.
    6. In the 3D-CAD simulation tree, expand 3D-CAD Model 1 > Design Parameters to review the design parameters.
  4. Extrude the sketch:
    1. Right-click the Features > Sketch 1 node and select Extrude.
    2. In the Extrude panel, accept all default settings and click OK.
  5. Click Close 3D-CAD.
Continue by defining global parameters that characterize the film entry conditions and draw ratio.
  1. To define the global parameters:
    1. In the Simcenter STAR-CCM+ simulation, right-click the Automation > Parameters node and select New > Vector.
    2. Rename the Parameters > Vector node as Die Exit Velocity and set the following properties:
      Property Setting
      Value [0.0043, 0.0, 0.0]
      Dimensions Length/Time (In the Dimensions dialog, set Length = 1 and Time = -1.)
    3. Create another parameter, a scalar parameter, and rename it as Die Exit Film Thickness.
    4. Select the Die Exit Film Thickness node and set the following properties:
      Property Setting
      Value 4.6E-4
      Dimensions Length
    5. Create another scalar parameter and rename it as Draw Ratio.
    6. Select the Draw Ratio node and set Value to 15.
  2. Save the simulation as filmCasting.sim.